VALVE MANUFACTURERS ASSOCIATION API 622 API 624

VALVE MANUFACTURERS ASSOCIATIONAPI 622 – API 624Written by Rich DavisManager Business Development Western Hemisphere &ChinaFlexitallic L.P., Deer Park, TexasPresented By: Steve Butler, Shell Global Solutions

FUGITIVE EMISSIONS SOURCESValves are considered to account for approximately60% of Fugitive Emissions of a RefineryFlanges,Pumps,15%Tanks, 10%Relief valves,15%Valve Stem, 80%Other Joints,20%*Source ‐ Monitoring and Containment of Fugitive Emissions from ValveStems, University of British Columbia, Vancouver

HISTORY – PERF 93-20 Testing started withthe PetroleumEnvironmentalResearch Forum –93-20 10 identical valves,with statisticalevaluation todetermine whichconditions causeemissions.

API-622API 622 Type Testing of Process ValvePacking for Fugitive EmissionsAPI STANDARD 622SECOND EDITION, AUGUST 2011

API-622 KEY CHANGE1.4 (Removed) Packing tested to this standardmay or may not perform the same when used ina manufacturer's valve. Performance to aspecified emission limit may be confirmed by retesting the packing in an actual valve inaccordance with Section 4.4 of this Standard.One of the single most important factorsconcerning the revision to the testing methodwas the removal of paragraph 1.4. With thisremoval, the test is no longer considered as analternative to ISO 15848-1.

API-622 Test fixture packing glanddimensions and tolerancesare listed in the standard.The test fixture is arrangedto follow the PERF testing.It relays the informationobtained in that testing. Mechanical cycles 1510The test fixture shall beequipped with an actuatorcapable of stroking the teststem to simulate themechanical cycle of a valveas follows: Rotating stem: Rate: 10 to 15 persecond Rotation: 90 5

TEST FIXTUREKey Information about the packing gland and tolerances required formanufacture are contained within the standard.

TEST PROCEDURETest Fluid: The test fluid used is dry methane gas,97% minimum purity, subjected to a temperature rangefrom ambient to 260ºC (500ºF) and pressures from 0to 4,137 kPag (0 TO 600 PSIG).

API-622 LEAK MEASUREMENT Leak measurementsconducted initially at the startof each day and at thecompletion of every 50 cycles.A minimum of ten (10)readings shall be taken over aone (1) minute duration. Theaverage reading shall becalculated and recorded.Any reading more than fiftypercent (50%) greater than theaverage, the readings shall berepeated. Leak measurement isconducted using a fixeddetection probe located atthe 12 o’clock positiondirectly above the potentialleak point.Leak measurements aretaken both in the static anddynamic condition.Dynamic conditionmeasurements are taken onthe opening and closingcycles and the average ofboth are recorded.The leak detector measures the combined flows fromthe stem OD and from the gland OD

API-622 EMISSIONS COLLECTION

API-622 WEIGHT LOSS TESTINGGraphite Foil Weight Loss Test Procedure Evaluate the ability of Graphite to resistoxidation. Testing using FSA test procedure FSA-G-604-07for oxidation of Graphite. Weight loss greater than 15% is not acceptable. This upper limit is a New Addition to thestandard.

API-622 PACKING CONSTRUCTIONBraided Packing Ring Conducted in an oven with fullexposure to air (oxygen-richenvironment).Select three test rings of asample packing set. If thepacking set is comprised ofmore than one type of packingring, each type is tested.Discontinue test if weight lossexceeds 50%.Lubricant Content PTFE content established bydetermining the % total fluorinein the packing, and comparingwith a base fluorine percentageof 76, as follows: Determine total percent offluorine content.Divide total percent offluorine by 0.76 to obtain theapproximate percent of PTFEcontent.

API-624Type Testing of Rising Stem ValvesEquipped with Flexible Graphite Packingfor Fugitive Emissions REVISED DRAFT – STILL IN REVIEW

API-624 The standard specifies the requirements andacceptance criteria (100 ppmv) for fugitive emissiontype testing of rising and rising-rotating stem valvesequipped with packing previously tested in accordancewith API Standard 622.Packing shall be suitable for use at servicetemperatures –29 C to 538 C (–20 F to 1000 F).The type testing requirements are based uponelements of EPA Method 21.Valves larger than NPS 24 and valves greater thanclass 1500 are outside the scope of this standard.

API-624 VALVE SELECTION & PRE-TEST The test valve shall be completely assembled and readyfor testing. The test valve shall be randomly selectedfrom manufacturer or distributor stock where such stockis available. For valves not in stock, the manufacturershall certify that the test valve was not modified in anyway to meet type test requirements and is a typicalrepresentation of the manufacturer’s stock product.Valve selection shall be approved by the purchaser.

API-624 VALVE SELECTION & PRE-TEST Body-bonnet and gland bolting torque shall be verified to be inaccordance with published manufacturer’s installationspecifications. Prior to type testing, it is permissible to operatethe test valve (at ambient temperature and under pressure) toensure that the packing is properly installed and consolidatedin the stuffing box.

API 624 TYPE TESTING The stem orientation for a test valve shall be verticalAs a safety precaution, the air in the valve cavity shallbe purged with an inert gas prior to starting thetesting.The test medium used shall be methane gas, 97%minimum purity.

API-624 TYPE TESTING Valves are subjected to a total of 310 mechanical cycles and3 thermal cycles. Mechanical cycling begins with the valveat ambient temperature.An optional low temperature test at -29 C (-20 F) may beperformed if requested by the purchaser.The elevated test temperature shall be 260 C 2 percent(500 F 5 percent).The test pressure shall be the lower of 600 psig or themaximum allowable pressure at 500 F per ASME B16.34for the applicable material group and shall be held constantthroughout the test.

API 624 ACTUATION The test valve may be equipped with a method ofactuation capable of stroking the stem to simulate themechanical cycle of a valve at the rate of 1 mm to 5mm (0.04 in. to 0.20 in.) per second. The method ofactuation should not impose additional side loads onthe stem or packing. Running torque values shall berecorded on the first and last cycle of testing.

API 624

API 624 LEAK MEASUREMENT Packing leakage measurements around the fullcircumference of the stem OD and packing OD and thehighest reading is recorded. Static and dynamic stemleakage measurements are be taken. Leak measurements are sniffed using a detection probe. No packing adjustment during type testing is permitted.

API624 ACCEPTANCE CRITERIA The Fugitive Emissions Test Report in AppendixA shall indicate “pass” when the measuredleakage throughout the test does not exceed100 ppmv.

API 624 VALVES QUALIFIED Allvalves of the same basic design as the test valvemay be deemed to have been type tested, subjectto the following additional limitations: For API 602 valves, a NPS ¾ class 800 test valvemay be used to qualify all valves NPS 1 and smallervalves up to and including class 800. For API 602valves, a NPS 1-1/2 class 800 test valve may beused to qualify all valves NPS 1-1/4 through NPS 21/2 up to and including class 800

API 624 VALVES QUALIFIED For API 602 valves, a NPS ¾ class 1500 test valvemay be used to qualify all valves NPS 1 and smaller inclass1500. For API 602 valves, a NPS 1-1/2 class1500 test valve may be used to qualify all valves NPS1-1/4 through NPS 2-1/2 in class 1500.For all other valves, a test valve may be used to qualifyvalves from two nominal sizes smaller to one nominalsize larger and one pressure class lower than the testvalve.

API 624 VALVES QUALIFIED Any change in valve stem sealing system designincluding, but not limited to, packing material,packing manufacturer, or packing type/modelrequires a re-qualification.If the location of the valve manufacturing facilitiesis different than what is listed on the API 624certificate, the purchaser may request requalification.

API 624 Post-test Inspection Valve shall be disassembled and components; including stem,packing, stem nut, gland follower, and stuffing box; shall beinspected and condition documented. Sealing components shall be photographed in accordancewith section 9.4.Recording and Documentation As a minimum, test results shall be provided on the FugitiveEmissions Test Report provided in Appendix A. Valves qualified by this standard shall be clearly andpermanently marked as “API 624”.

THANK YOUQuestions?

API 624 VALVES QUALIFIED For API 602 valves, a NPS ¾ class 1500 test valve may be used to qualify all valves NPS 1 and smaller in class1500. For API 602 valves, a NPS 1-1/2 class 1500 test valve may be used to qualify all valves NPS 1-1/4 through NPS 2-1/2 in class 1500. For all other